Continuously Variable Transmission System

ABSTRACT

The invention relates to a continuously variable transmission (CVT) system, governed by an inertia mechanism that provides an additional degree of freedom, conferring dynamic properties on the transmission. The complete system includes three distinct subsystems. The first subsystem transforms the rotating movement from the drive system into a movement with oscillating angular speed and regulates the amplitude of said movement. The oscillating rotation at the output of the first subsystem is used to drive the second subsystem, which acts as a regulating element by means of the inertia mechanism. In this manner, the second subsystem acts as a torque-regulating element, providing a signal representing the oscillating angular speed at the output shaft thereof. The oscillating rotation at the output of the second subsystem is rectified in the third subsystem, thereby providing a signal representing angular speed in a single direction of rotation at the output shaft.

OBJECT OF THE INVENTION

This invention, as expressed in the heading of this descriptive memory refers to a continuously variable transmission system with inertia regulation.

It basically includes three subsystems that are related to each other, in a manner that the first of them provides an oscillating angular speed with variable amplitude, a second subsystem that includes an inertia mechanism and a third subsystem with movement rectification, which provides a single direction of rotation at its output.

Since this is a continuously variable transmission system, it includes a limited number of transmission ratios within the possible gear ratio interval, while a continuous variation in the transmission ratio may be obtained.

This invention has a direct application in the automobile industry, in any industrial application that requires a power transmission system as well as in any other application that requires torque regulation and changes in speed.

BACKGROUND OF THE INVENTION

Fixed ratio transmissions, regardless of whether they are manual or automatic, include a discrete number of transmission ratios or gears. In comparison with conventional transmissions, in a continuously variable transmission or CVT, the transmission ratio between the input and output shafts may be progressively varied in a specific interval of possible ratios. The possibility of incorporating a limited number of transmission ratios provides an added parameter in order to optimize one or several variables of the vehicle. This way, with a specific variation in the transmission ratio, we can achieve conditions of high power, low consumption or a compromised ratio between both variables.

One possible classification establishes two large groups of continuously variable transmissions, the cinematic and dynamic types. In a cinematic CVT, the progressive change in transmission ratio is carried out on a specific element, resulting in the transmission ratio being fixed at a specific value and requires acting upon the element once again in order to change it. On the other hand, in a dynamic type CVT, as well as being able to act upon a cinematic regulation element, the transmission ratio also depends on the external conditions to which the transmission is subjected to. This means that the transmission ratio will be determined by the cinematic characteristics as well as by variables such as the speed of the input shaft or the resistant torque exerted on the output shaft.

The dynamic type continuously variable transmissions originate from the innovative work carried out by Hunt, which were published in GB patents 21,414 of 1912 and GB Patent 19,904 of 1913, where an inertia type transmission system is described with the dynamic transmission principle but without a direct application like CVTs.

The first documented continuously variable type dynamic transmission originates from the work of Constantinesco, described in his GB Patent 185,022 of 1922 and in his subsequent patents, which describe methods for improving the power transmission of the primary shafts of vehicles that operate using internal combustion engines. In these transmissions, the torque is regulated using a pendulum or other inertia elements.

Chalmers, in U.S. Pat. No. 1,860,383 of 1932 introduces his oscillating torque transmission system with movement of the output shaft in a single direction of rotation. In this case, the regulating element consists of a series of satellite gears with eccentric masses that generate an oscillating torque at the output due to the inertia forces these masses are subjected to. Similar type transmissions were designed by Tam, 1992 (U.S. Pat. No. 5,134,894) and Fernandez, 1998 (U.S. Pat. No. 5,833,567), which were also based on satellite gears with eccentric masses. Also with oscillating masses, but in this case without these carrying out complete rotations about themselves, we have the torque exchange patent of 1982 owned by Shea (U.S. Pat. No. 4,336,870); this transmission includes two symmetric masses shaped like a cam that oscillate, thus regulating the torque of the output shaft. Also based on inertia regulation using eccentric masses we have William's torque converter of 1971 (U.S. Pat. No. 3,581,584).

Two dynamic type transmission patents exist previous to the one mentioned above that use the same principle of operation to solve different technical problems. The first one is U.S. Pat. No. 5,860,321 of 1999 provided by Williams, where he proposes new solutions for rectifying movement using a differential rectifier with two free wheels as well as specific configurations and new technical solutions focussed on increasing the compactness as well as the efficiency of the power transmission. The second transmission of this type provided by Lester in 2000 (U.S. Pat. No. 6,044,718) proposes solutions among which a power transmission regulation system stands out. The complete system is a CVT with inertia regulation and with the possibility of being coupled.

SUMMARY OF THE INVENTION

The invention consists of a continuously variable transmission system with inertia regulation. Regulation is carried out using an inertia mechanism comprised of an epicyclic train that provides an additional degree of freedom. A specific mass is added to the element of the epicyclic train that includes this degree of freedom, which provides a dynamic character to the transmission and causes the train to act as a regulating element of the output shaft resistant torque. The complete system includes three different subsystems. A first subsystem that converts the signal provided by the drive system into an oscillating angular speed signal while it regulates the amplitude of said speed signal. This angular speed is used to drive the epicyclic train, which constitutes the second subsystem and is the inertia regulation mechanism for the transmission. This way, the second subsystem provides an oscillating torque regulated signal. The oscillating signal at the output of the second subsystem must be rectified in the third subsystem. In this manner, an angular speed signal in a single direction of rotation is finally obtained at the output shaft. Thus, a unidirectional torque capable of overcoming the resistant torque is applied at the transmission output shaft. This way, the complete system provides a torque that is adapted to the operating conditions it is subjected to such as the angular speed of the transmission input shaft as well as the resistant torque at the output shaft. Therefore, the invention consists of a dynamic type continuously variable transmission system with an oscillating nature.

The transmission system described in the object of this patent includes many advantages, among which the following are highlighted:

-   It does not require using any type of clutch system. -   The transmission system regulates itself providing a change ratio     between the output and input shafts that is most adequate for the     demands that the system is subjected to. -   Since this is a continuously variable transmission system, it     includes a limited number of transmission ratios within the interval     of possible change ratios. -   A continuous variation of the transmission ratio can be obtained in     order to achieve specific operating conditions of high power, low     consumption or a compromise relation between both variables.

From a commercial point of view, the characteristics of this transmission system are of great interest to the industry.

This transmission system has a direct application in the automobile industry, in any industrial application that requires a power transmission system as well as in any other application that requires torque regulation and speed changes.

In order to provide a better explanation of this descriptive memory and as an integrating part thereof, figures are included below, which in an illustrative and not limiting manner represent the object of this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1.—Consists of a detailed schematic representation of the three subsystems that comprise the complete transmission and the manner in which these are connected.

FIG. 2.—Consists of a schematic representation of subsystem S1 corresponding to the driving and amplitude regulation mechanism.

FIG. 3.—Consists of a schematic representation of subsystem S2 corresponding to the transmission's inertia regulation mechanism.

FIG. 4.—Consists of a schematic representation of subsystem S3 corresponding to the oscillating movement rectification at the inertia regulation mechanism's output.

FIG. 5.—Represents the transmission flow of movement in a determined oscillating direction of the output shaft of subsystem S2.

FIG. 6.—Represents the transmission flow of movement in the direction opposite the oscillation with respect to the previous output shaft of subsystem S2.

FIG. 7.—Consists of a schematic representation of the driving mechanism for the reference position corresponding to the minimum oscillation amplitude.

FIG. 8.—Consists of a schematic representation of the driving mechanism for the position corresponding to the maximum oscillation amplitude.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The inertia element of the developed dynamic CVT is comprised of an epicyclic reducer with mass added to the crown. Said epicyclic reducer is inserted upside down into the CVT; therefore, the reducer's input shaft is connected to the satellite holder and the output shaft to the planet. Therefore, in an assembly of this type, the epicyclic reducer would be multiplying the input speed.

The transmission regulation is based on the aforementioned property of the inertia element and the assembly. When acceleration is applied to the satellite holder while the planet is maintained blocked, the crown's response is to accelerate with a similar type of outcome. Due to the acceleration experienced by the crown and while this acceleration lasts, a torque is generated at the planet. Once the crown acceleration process ceases, the torque at the planet is null.

As a consequence, by subjecting the satellite holder to a speed law that produces continuous accelerations, a resistant torque can be overcome at the output shaft. For this purpose, an angular speed law is used at the input shaft in the form of an oscillating signal, which is generated by means of a driving mechanism. At the same time, the driving mechanism regulates the amplitude of said angular velocity. The signal at the planet also has an oscillating nature; therefore, a movement rectifying mechanism is required.

The crown movement carries with it an additional degree of freedom. The adding of mass to the epicyclic train's crown allows said element to become a power regulation inertia mechanism. This regulation consists of cyclic power accumulations and cessions that allow the transmission to adapt to each one of the operating conditions it is subjected to.

As seen in the FIG. 1, the complete transmission system includes three subsystems positioned in series.

The purpose of the first subsystem S1 (FIG. 2) is to transform the signal originating from the drive system through shaft E1 (FIGS. 1 and 2) into an angular oscillating speed signal with a variable amplitude at shaft E2 (FIGS. 1, 2 and 3); this shaft is the input to the second subsystem S2 (FIG. 3). Bar B1 (FIGS. 1 and 2) consists of a handle with a fixed radius R, which transmits the circular movement of its end to control gear EC (FIGS. 1 and 2). This EC element is engaged with the control crown CC (FIGS. 1 and 2) and spinning about the inner face of the crown, while said crown is fixed in its position as determined by the driving element EA (FIGS. 1 and 2). Said EA element uses a worm gear to drive the outer face of control crown CC in order to control its relative position with respect to the reference position, corresponding for example, to the minimum oscillating amplitude (FIG. 7). Bar B2 (FIGS. 1 and 2) is joined at a point P (FIGS. 1 and 2) to the EC, with said point located at a radius R from the centre of the EC. The union at point P is carried out in such a manner to allow the relative turn between the EC elements and B2.

In the previous arrangement of subsystem 51, the diameter of control gear EC is equal to the radius of the inner face of control crown CC. Under this configuration, the hypocycloid curve generated by point P and therefore, the end of bar B2 at said point, degenerates to a straight line that is described by the inner diameter of control crown CC. Driving shaft EA and modifying the position of crown CC with respect to the reference position, the different possible diameters are described. This way, the oscillation transmitted through bar B2 to counterweight B3 (FIGS. 1 and 2) is a function of the described diameter and will vary from an oscillation corresponding to a minimum amplitude at the reference position (FIG. 7) to that which generates a maximum amplitude (FIG. 8), and which corresponds to an amplitude that is out of phase at a right angle with respect to the reference angle.

The second subsystem S2 (FIG. 3) uses the oscillating signal at the output of the first subsystem S1, acting as a torque regulating element by means of an inertia mechanism consisting of an epicyclic train, to which a mass M is added at crown C (FIGS. 1 and 3). The satellite holder PS is joined to satellites SA1-SA3 by means of the corresponding shafts ESA1-ESA3 as shown in FIGS. 1 and 3. These satellites are engaged to crown C as well as to planet PL (FIGS. 1 and 3), in a manner so the oscillating movement is transmitted to both elements. A mass M is uniformly added to crown C, with which said crown acquires the function of the transmission's inertia regulation element. Two predominant power transmission modes exist in subsystem S2, through which power is transmitted from the E1 input shaft to the E4 output shaft (FIGS. 1 and 4). The power is transmitted in a manner that the law of oscillating angular accelerations that is exerted over the crown causes accelerations and decelerations of the crown associated with kinetic energy accumulations and cessions of subsystem S2. In the first of the operating modes, the power supplied to the transmission through shaft E1 is used to accelerate crown C, which accumulates kinetic energy and in providing torque to output shaft E4. In the second mode, the power supplied by input shaft E1 as well as the power released by crown C as it decelerates are used to supply torque to output shaft E4. A brief transition period exists between these two main modes of operation.

The third subsystem S3 (FIG. 4) transforms the oscillating signal coming from subsystem S2 into a single direction of rotation. This subsystem S3 consists of a rectifier mechanism that is based on free wheels or any other type of mechanical diodes. The movement of shaft E3 (FIGS. 1, 3 and 4), output shaft of subsystem S2 and input to subsystem S3, transmits its rotating movement to gear ER2 as well as to ER5 through gear ER1 as shown in FIGS. 1 and 4.

When the oscillating movement transmitted through shaft E3 rotates clockwise, free wheel RL1 (FIGS. 1 and 4) located on the outside of gear ER2 is engaged, while free wheel RL3 (FIGS. 1 and 4), located on the inside of gear ER5 is disengaged. Therefore, in this configuration the movement is transmitted only through gear ER2, which in turn transmits the movement of gear ER3 (FIGS. 1 and 4) by means of shaft divider ED1 (FIGS. 1 and 4). The movement of gear ER3 is transmitted to gear ER4 (FIGS. 1 and 4), which spins attached to the satellite holder of the movement rectifier mechanism PSR (FIGS. 1 and 4). The direction of rotation of the satellite holder is transmitted to the rectifier mechanism's planet and therefore to output shaft E4 by means of satellites SAR1-SAR3 (FIGS. 1 and 4). In this configuration where shaft E3 turns clockwise, the crown of the rectifier mechanism CR (FIGS. 1 and 4) remains blocked; in other words, with a null angular speed. Since the tendency of the crown CR in this configuration, for a clockwise rotation of the satellite holder PSR would be to rotate in the opposite direction, free wheel RL4 (FIGS. 1 and 4), which is located in gear ER6 (FIGS. 1 and 4), is included in order to cancel its movement in that direction keeping crown CR blocked.

By the contrary, when the oscillating movement that is transmitted through shaft E3 is counter-clockwise, free wheel RL3 located inside gear ER5 is engaged while free wheel RL1 located inside gear ER2 is disengaged. In this configuration, the movement is transmitted only through gear ER5, which transmits the movement to gear ER6 through divider shaft ED2 (FIGS. 1 and 4). The movement of gear ER6 is transmitted to the crown CR, which will rotate counter-clockwise. In this configuration where the crown of the rectifier mechanism CR rotates counter-clockwise, the satellite holder would tend to rotate counter-clockwise and therefore, it would force gear ER4 to rotate in that direction, which rotates attached to the satellite holder PSR. This momentum would cause gear ER3 to turn clockwise. This momentum would be cancelled by the installation of free wheel RL2 (FIGS. 1 and 4), which would cause the satellite holder PSR to be blocked. In this configuration, all of the crown's movement is transmitted to output shaft E4, which would turn clockwise.

This way, when shaft E3 turns clockwise, the power transmission is carried out as shown in FIG. 5, while as shaft E3 turns counter-clockwise, the power transmission is carried out as shown in FIG. 6. This way, the oscillating movement is transformed into a single direction of rotation, taking advantage of the oscillating movements of shaft E3 in both directions in order to overcome a determined load value at the output shaft of transmission E4.

In subsystem S3, which includes the movement rectifier mechanism described herein, the adequate ratios between gears should be maintained in order for the rotation of the output shaft corresponding to both aforementioned configurations to be of equal magnitude for each of them. With this, the torque transmitted by subsystem S2 at shaft E3 would be symmetrical for a specific load value at the transmission's output shaft E4. This way, the operation of subsystem S2, the inertia regulation mechanism and therefore, of the entire transmission would be as symmetrical and regular as possible. 

1.-24. (canceled)
 25. A continuously variable transmission system that is characterized in that it includes at least: a first drive and regulation subsystem that transforms a rotating movement of a drive element connected to its input shaft into a oscillating angular movement with a variable amplitude at an output shaft of this subsystem; a second torque inertia regulation subsystem that incorporates at least an additional mass and an input shaft that receives the oscillating movement with a variable amplitude of the first subsystem, obtaining an oscillating angular movement at an output shaft of the second subsystem; a third movement rectification subsystem that converts the oscillating movement it receives from the second subsystem into a single direction of rotation at an output shaft of the third subsystem.
 26. A continuously variable transmission system in accordance with claim 25, characterized in that the subsystems are arranged independently.
 27. A continuously variable transmission system in accordance with claim 25, characterized in that the subsystems are partially grouped with each other.
 28. A continuously variable transmission system in accordance with claim 25, characterized in that the subsystems are completely grouped with each other
 29. A continuously variable transmission system in accordance with claim 25, characterized in that the first subsystem incorporates at least one drive mechanism that generates a movement with a variable amplitude, oscillating and centred at zero.
 30. A continuously variable transmission system in accordance with claim 25, characterized in that the first subsystem incorporates at least one drive mechanism that generates a movement with a variable amplitude, oscillating and not centred at zero.
 31. A continuously variable transmission system in accordance with claim 25, characterized in that the torque inertia regulation subsystem includes at least one epicyclic train.
 32. A continuously variable transmission system in accordance with claim 25, characterized in that the torque inertia regulation subsystem includes at least one differential mechanism.
 33. A continuously variable transmission system in accordance with claim 25, characterized in that the added mass is driven directly by any element of the torque inertia regulation subsystem.
 34. A continuously variable transmission system in accordance with claim 25, characterized in that the added mass is driven indirectly by any element of the torque inertia regulation subsystem.
 35. A continuously variable transmission system in accordance with claim 25, characterized in that the torque inertia regulation subsystem incorporates at least one differential mechanism installed in series.
 36. A continuously variable transmission system in accordance with claim 25, characterized in that the torque inertia regulation subsystem incorporates a combination of at least one differential mechanism installed in parallel.
 37. A continuously variable transmission system in accordance with claim 25, characterized in that an out of phase drive mechanism is added to the first drive and regulation subsystem.
 38. A continuously variable transmission system in accordance with claim 25, characterized in that the first subsystem incorporates at least two oscillating signal generating mechanisms for the purpose of improving a balance or for any other purpose.
 39. A continuously variable transmission system in accordance with claim 25, characterized in that the amplitude of the oscillating output speed of the first subsystem is not regulated, and therefore the entire subsystem acts as a torque converter.
 40. A continuously variable transmission system in accordance with claim 25, characterized in that the first subsystem incorporates a bar (B2) acting as a rod connected to a rear bar acting as a rocker arm (B3) attached to the output shaft (E2) and also connected at a radial point (P) of a control gear (EC) that is associated with a crown (CC), while this control gear is coupled to a shaft associated with the initial input shaft (WE) by means of a bar (B1).
 41. A continuously variable transmission system in accordance with claim 40, characterized in that it incorporates a drive element (EA) like a worm gear, associated with the crown (CC) of the first subsystem (S1) for the purpose of regulating the amplitude of the angular speed of output shaft (E2) of said subsystem.
 42. A continuously variable transmission system in accordance with claim 31, characterized in that the epicyclic train of the second inertia regulation subsystem (S2) includes a satellite holder (PS), which is attached to input shaft (E2), satellite gears, (SA1) to (SA3), that engage with an inner face of crown (C) of that epicyclic train, which has a distributed mass (M) and a planet gear (PL), which is attached to the output shaft (E3) of the second inertia regulation subsystem (S2).
 43. A continuously variable transmission system in accordance with claim 25, characterized in that the third rectifying subsystem includes at least the following: an epicyclic train; a rectification based on the use of a plurality of free wheels, other type of mechanical diodes or a system that allows dividing the power flow into several paths, so a subsequent sum of these paths of flows causes a movement in a single direction of rotation of the output shaft, since it partially or completely as an alternative, restricts a degree of additional freedom of the epicyclic train.
 44. A continuously variable transmission system in accordance with claim 25, characterized in that the rectifying subsystem includes at least the following: a differential mechanism; a rectification based on the use of a plurality of free wheels, other type of mechanical diodes or a system that allows dividing the power flow into several paths, so a subsequent sum of these paths of flows causes a movement in a single direction of rotation at the output shaft, since it partially or completely as an alternative, restricts a degree of additional freedom of the differential mechanism.
 45. A continuously variable transmission system in accordance with claim 43, characterized in that the movement rectification subsystem (S3) includes an epicyclic train, whose output shaft (E4), which always rotates in a single direction, can receive the movement from input shaft (E3), which is attached to a gear (ER1) by means of a first transmission cycle that changes a direction of rotation of that shaft (E4) and by means of a second transmission cycle that maintains a direction of rotation from input shaft (E3) to output shaft (E4).
 46. A continuously variable transmission system in accordance with claim 45, characterized in that the transmission cycles of the movement rectification subsystem (S3) include: two divider shafts (ED1) and (ED2), to which two pairs of rear gears are connected (ER2) and (ER5) that engage with an input gear (ER1) and two front gears (ER6) and (ER3), respectively associating a plurality of free pinions (RL1), (RL3), (RL4), and (RL2), with those two pairs of gears and which may be anchored or not to their respective gears; a gear (ER4) that engages with one of the rear gears (ER3) while that gear (ER4) is attached to a satellite holder (PSR) that drags satellites (SAR1) to (SAR3), and at the same time are engaged to a crown gear (CR) and to a planet gear (PR) of the epicyclic train, the planet gear (PR) is connected to output shaft (E4); a gear connected to the crown gear (CR) of the epicyclic train and is engaged with rear gear (ER6).
 47. A continuously variable transmission system, characterized in that it incorporates a rectification subsystem that includes at least the following: an epicyclic train; a rectification based on the use of a plurality of free wheels, other type of mechanical diodes or a system that allows dividing the power flow into several paths, so a subsequent sum of these paths of flows causes a movement in a single direction of rotation at the output shaft, since it partially or completely as an alternative, restricts a degree of additional freedom of the epicyclic train.
 48. A continuously variable transmission system, characterized in that it incorporates a rectification subsystem that includes at least the following: a differential mechanism; a rectification based on the use of a plurality of free wheels, other type of mechanical diodes or a system that allows dividing the power flow into several paths, so a subsequent sum of these paths of flows causes a movement in a single direction of rotation at an output shaft, since it partially or completely as an alternative, restricts a degree of additional freedom of the differential mechanism. 